Repair Report (DC Motor) : Rockwell Automation

Repair Report (DC Motor)
Customer
Order
Number
Rockwell Automation
Job No
EA 052903
Description 250 Hp DC Motor

Make Reliance
Frame
C4414 ATZ
Model
12438101
Outgoing Photo
Power (Kw) 250 Hp

Speed (rpm) 850 / 2000
Voltage (v) 500 v Arm, 300 v Field
Current (A) 397 A, Arm, 18.83 A Field
Winding Shunt
Mounting Foot B3
Reported Faults / Customer Observations

Repeated failure of Drive End bearing
12 -13 months after servicing
Date
Nameplate
14 February 2010
60481
Fletcher Moorland Ltd. Elenora Street, Stoke on Trent, ST4 1QG

Tel - 01782 411021 web - www.fletchermoorland.co.uk
Inspection / Test Run

Test Run Conformance Check
Comments
High amplitude, high frequency vibration velocity and acceleration most noticeable at position 2 (drive
end) of the motor. Expectation of drive end bearing damage.
Incoming Photo
Stripdown report
The motor was relatively clean externally, internally there

was evidence of carbon dust contamination. A foot was
found to be broken on the resolver feedback module and a
louvred brushgear cover was damaged. The NDE bearing
was in good condition and the lubrication appeared clean.
The DE bearing was rough to turn by hand and the
lubrication appeared carburised. The NDE bearing housing
was oversize @ 170.035 mm.
Failure Photo
Failure Analysis
The DE bearing was removed, cleaned and dismantled. It

was evident from our failure analysis the bearing has
suffered electrical current discharge damage. Further
photos of the damaged bearing are shown later in this
report.

Mechanical Fits & Data

Journal Measurements - DE
Journal Measurements - NDE

Bearing 6219 C3
Bearing 6222 C3
Fit
Fit
Nominal 95
Nominal 110
mm
Up Tol 110.028 mm
Up Tol 95.018 mm
Lo Tol 95.003 mm
Lo Tol 110.010 mm
Shaft size 3.6248 "
Pass
Fail
8 Point Measurements
Keyway 0.845 "
Pass
Fail
110.012
110.012
Pass
Fail
110.012
110.012
Bearing Shoulder run-out Pass
Fail
110.012
110.012
110.012
110.012
Bearing Shoulder run-out Pass
Fail
95.015
95.015
95.015
95.015
95.012
95.012
95.015
95.015
Pass
Fail
Shaft run-out 0.01 mm
Housing Measurements - NDE
Up Tol 170.025
Pass
Nominal size 200
Lo Tol 170.000
170.020
170.020
200.015
200.015
170.020
170.020
200.015
200.015
170.020
170.020
200.015
200.015
170.020
170.020
200.015
200.015
Pass
Fail
Pass
Rotor Balance Data

Balance grade G1.0
G2.5
Balance grade to ISO 1940/1 : 2003 Part 1
Foot Flatness
0.05
0.00
Permitted (g)
Actual (g)
Position (Deg)
NDE
14.76
2.99
232
DE
14.76
10.80
52
0.05
No of Bars
0.05
Total Indicated
11
Run-out (TIR)
Motor viewed
from above
Fail
Plane
Commutator Profile
0.00
162
TIR Reading
Good > 50 um
Satisfactory > 75 um
microns (um)
Comments
0.00
0.00
0.00
mm
Lo Tol 200.000
Up Tol 200.028
0.00
Fail
Housing Measurements - DEEE
mm
Nominal size 170
0.00
mm
0.00
NDE housing was oversize 170.035 mm on

inspection.
0.00
Commutator Profile
Commutator Profile (Blue trace- as received, Red trace- after machining)
P rofilr MAS - Com m u!a tor- Radi:a I
Plot
-1
v;0
40
-..!.
+
o]J
EO
<I)
;;:I
\-\.-
t:
}.:.
'
...-
\;,
\
-1
80
100
Fl:!cord ing
Pbt
Fl:!oo.:irg 1
Fl:!oo.:irg 1
-100
100
1
Rec;
Recording
s !9 rt
10 (1 0:52:37 am)
15 Jon 2J) 10 (12:07:18 prn)
2f; Jon 2fJ
-1
-100
Max BTB
tiJdQ SiLe
Ra.d:al TIR
Scale (+f.. 100 MiciD'ils)
( 1 2) 12 B<rs
( 187) 17 B<rs
11 IJnl :52-12
941-Jrn : 99-100
3 : 21-22
32:100.109
Mean BTB
Std V SUS Ct
HiMi::a
1D
4.4
02
4.7
0
1
Fletcher Moorland Ltd. Elenora Street, Stoke on Trent, ST4 1 OG

Tel- 01782 411021 web- www.fletchermoorland.co.uk
0
0
Fl:!marK
Repair Details / Service Report

The motor was fully stripped down and all mechanical parts were checked for correct fit and tolerance.
The NDE bearing housing was found to be oversize 170.035 mm (Tolerance 170.025mm - 170.000mm)
The housing was bored, sleeved and machined to 170.020 mm. All mechanical parts were blast
cleaned and all interior surfaces were spray painted with an anti-track paint. The windings were cleaned
and checked for integrity. All winding temperature control devices were checked for correct function.The
commutator was profiled before being skimmed, undercut and chamfered. A finished profile was
recorded. The armature was dual plane dynamically balanced to an enhanced G1.0 balance grade for
low vibration operation. The resolver feedback module was checked for correct function and outputs
(2,2v pk vector, 2,2v pk SIN, 2,2 vpk COS) Mechanical repairs were carried out to the resolver foot and
louvred brushgear panels. A genuine SKF insulated bearing was fitted to the NDE of the motor (6219
C3 VL0241) A SKF 6222 C3 was fitted to the DE.
The motor was assembled and 16 pairs of new brushed were fitted and bedded in.
The motor was run on our test bed and SKF conformance check results were taken and recorded.
The motor was spray painted and packaged ready for delivery.
Electrical Data - Static Test

Insulation
Resistance (IR)
Winding
Resistance
Earth leakage
Field Circuit
999
MOhm @
Ohms
Winding
Resistance
0.013 0.014
Earth leakage
7.62
500
15.1
uA @
3.42
Armature Circuit
999
500
Insulation
Resistance (IR)
1800
Electrical Data - Run Test
Ohms
uA @
1800
Load test
No load test
Voltage - Armature
356
Voltage - Armature
Current - Armature
14.6
Current - Armature
Voltage - Fields
50
Voltage - Fields
Current - Fields
4.3
Current - Fields
Motor Speed
rpm
Measured Output Power
Kw
Motor Speed
1485
rpm (CW)
Motor Speed
1486
rpm (CCW)

MOhm @
Measured Output Torque

Nm
Mechanical Conformance Check Data & Vibration Analysis

Conformance Check
Vibration Analysis
Comments
The final test run show the motor has passed the SKF conformance check. Compared to the initial test
run all vibration levels are within limits for each band.
This motor has been fitted with an insulated bearing fitted on the NDE of the motor. Do not allow any
ground connection to be made to this bearing by fitting temperature sensing or other metallic
conductors.

Further Analysis / Information

Photo
Description
Evidence of carbonisation of lubricant as found on

stripdown, note the fresh lubricant evident on the outer
race of the bearing. (this has not entered the bearing
and has not been subjected to electrical current
discharge.
Photo
Description
Frosting evident on the inner raceway of the bearing.
Photo
Description
fluting evident on the outer raceway of the bearing.


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Repair Report (DC Motor)

Description 250 Hp DC Motor

Power (Kw) 250 Hp

Reported Faults / Customer Observations

Fletcher Moorland Ltd. Elenora Street, Stoke on Trent, ST4 1QG

Inspection / Test Run

The motor was relatively clean externally, internally there

The DE bearing was removed, cleaned and dismantled. It

Fletcher Moorland Ltd. Elenora Street, Stoke on Trent, ST4 1QG

Mechanical Fits & Data

Journal Measurements - NDE

Keyway 0.845 "

Bearing Shoulder run-out Pass

Bearing Shoulder run-out Pass

Shaft run-out 0.01 mm

Housing Measurements - NDE

Nominal size 200

Rotor Balance Data

Balance grade to ISO 1940/1 : 2003 Part 1

Housing Measurements - DEEE

Nominal size 170

NDE housing was oversize 170.035 mm on

Tel - 01782 411021 web - www.fletchermoorland.co.uk

2f; Jon 2fJ

Fletcher Moorland Ltd. Elenora Street, Stoke on Trent, ST4 1 OG

Repair Details / Service Report

Electrical Data - Static Test

Electrical Data - Run Test

Measured Output Power

Fletcher Moorland Ltd. Elenora Street, Stoke on Trent, ST4 1QG

Measured Output Torque

Fletcher Moorland Ltd. Elenora Street, Stoke on Trent, ST4 1QG

Mechanical Conformance Check Data & Vibration Analysis

Fletcher Moorland Ltd. Elenora Street, Stoke on Trent, ST4 1QG

Further Analysis / Information

Evidence of carbonisation of lubricant as found on

Frosting evident on the inner raceway of the bearing.

fluting evident on the outer raceway of the bearing.

Fletcher Moorland Ltd. Elenora Street, Stoke on Trent, ST4 1QG

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